Egg carton with lugless denest-feature and related methods

Abstract

An egg carton may include a lid having first and second opposing longitudinal sides, first and second opposing ends, a major surface, and first and second denest-features respectively near the first and second opposing ends. Each denest-feature may have an upper wall extending from the major surface, an outward flange being parallel to the major surface, and a curved surface extending from the upper wall to the outward flange. The egg carton may include a base having first and second opposing longitudinal sides, first and second opposing ends, and lower egg receptacles for receiving corresponding eggs, and a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.

That which is claimed is: 
     
         1 . An egg carton comprising:
 a lid comprising
 first and second opposing longitudinal sides, 
 first and second opposing ends between said first and second opposing longitudinal sides, 
 a major surface extending between said first and second opposing longitudinal sides and said first and second opposing ends, and 
 first and second denest-features respectively adjacent said first and second opposing ends, each denest-feature comprising
 an upper wall extending from said major surface, 
 an outward flange being substantially parallel to said major surface, and 
 a curved surface extending from said upper wall to said outward flange; 
 
   a base comprising first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and   a hinge strip coupled between said lid and said base and configured to permit said lid to fold between a closed position and an open position.   
     
     
         2 . The egg carton of  claim 1  wherein said base comprises a plurality of posts between said plurality of lower egg receptacles. 
     
     
         3 . The egg carton of  claim 2  wherein said plurality of posts comprises first posts and second posts, said second posts having a height less than that of said first posts. 
     
     
         4 . The egg carton of  claim 3  wherein adjacent first posts include a respective second post therebetween. 
     
     
         5 . The egg carton of  claim 1  wherein said major surface of said lid is flat. 
     
     
         6 . The egg carton of  claim 1  wherein said upper wall extends vertically along opposing sides of said curved surface. 
     
     
         7 . The egg carton of  claim 1  wherein said upper wall is canted at an angle of 6-10 degrees from an axis perpendicular to said major surface of said lid. 
     
     
         8 . The egg carton of  claim 1  wherein each denest-feature is lugless. 
     
     
         9 . The egg carton of  claim 1  wherein each lower egg receptacle comprises first and second pairs of opposing curved protrusions. 
     
     
         10 . The egg carton of  claim 9  wherein each lower egg receptacle comprises a bottom surface between said first and second pairs of opposing curved protrusions and comprising a dimple for receiving a respective egg. 
     
     
         11 . An egg carton comprising:
 a lid comprising
 first and second opposing longitudinal sides, 
 first and second opposing ends between said first and second opposing longitudinal sides, 
 a flat major surface extending between said first and second opposing longitudinal sides and said first and second opposing ends, and 
 first and second denest-features respectively adjacent said first and second opposing ends, each denest-feature comprising
 an upper wall extending from said flat major surface, 
 an outward flange being substantially parallel to said flat major surface, and 
 a curved surface extending from said upper wall to said outward flange, said upper wall extending vertically along opposing sides of said curved surface; 
 
   a base comprising
 first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, 
 a plurality of lower egg receptacles for receiving a corresponding plurality of eggs, and 
 a plurality of posts between said plurality of lower egg receptacles; and 
   a hinge strip coupled between said lid and said base and configured to permit said lid to fold between a closed position and an open position.   
     
     
         12 . The egg carton of  claim 11  wherein said plurality of posts comprises first posts and second posts, said second posts having a height less than that of said first posts. 
     
     
         13 . The egg carton of  claim 12  wherein adjacent first posts include a respective second post therebetween. 
     
     
         14 . The egg carton of  claim 11  wherein said upper wall is canted at an angle of 6-10 degrees from an axis perpendicular to said flat major surface of said lid. 
     
     
         15 . The egg carton of  claim 11  wherein each denest-feature is lugless. 
     
     
         16 . The egg carton of  claim 11  wherein each lower egg receptacle comprises first and second pairs of opposing curved protrusions; and wherein each lower egg receptacle comprises a bottom surface between said first and second pairs of opposing curved protrusions and comprising a dimple for receiving a respective egg. 
     
     
         17 . A method of making an egg carton comprising:
 forming a lid comprising
 first and second opposing longitudinal sides, 
 first and second opposing ends between the first and second opposing longitudinal sides, 
 a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and 
 first and second denest-features respectively adjacent the first and second opposing ends, each denest-feature comprising
 an upper wall extending from the major surface, 
 an outward flange being substantially parallel to the major surface, and 
 a curved surface extending from the upper wall to the outward flange; 
 
   forming a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and   forming a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.   
     
     
         18 . The method of  claim 17  wherein the base comprises a plurality of posts between the plurality of lower egg receptacles. 
     
     
         19 . The method of  claim 18  wherein the plurality of posts comprises first posts and second posts, the second posts having a height less than that of the first posts. 
     
     
         20 . The method of  claim 19  wherein adjacent first posts include a respective second post therebetween. 
     
     
         21 . A method of packaging a plurality of eggs in an egg carton, the method comprising:
 positioning the plurality of eggs in the egg carton, the egg carton comprising
 a lid comprising
 first and second opposing longitudinal sides, 
 first and second opposing ends between the first and second opposing longitudinal sides, 
 a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and 
 first and second denest-features respectively adjacent the first and second opposing ends, each denest-feature comprising
 an upper wall extending from the major surface, 
  an outward flange being substantially parallel to the major surface, and 
 a curved surface extending from the upper wall to the outward flange; 
 
 
 a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and 
 a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position. 
   
     
     
         22 . The method of  claim 21  wherein the base comprises a plurality of posts between the plurality of lower egg receptacles. 
     
     
         23 . The method of  claim 22  wherein the plurality of posts comprises first posts and second posts, the second posts having a height less than that of the first posts. 
     
     
         24 . The method of  claim 23  wherein adjacent first posts include a respective second post therebetween.